Calculating Emissions From Coating And Painting Operations
FACT SHEETOffice of Compliance Assistance and Pollution PreventionSeptember 2014Calculating Emissions from Coating and Painting OperationsThis guide explains how to calculate emissions of volatile organic compounds (VOC),hazardous air pollutants (HAP) and select toxic air contaminants (TAC) from commoncoating and painting operations. This emissions information is needed for air permitapplications and for ongoing recordkeeping and reporting requirements for air permits.This guide includes example calculations that cover the most common scenarios and permit requirements. A briefbackground on why U.S. EPA regulates emissions from painting operations and the basics of coating formulations ishelpful in understanding the concepts of the calculations and the requirements of common air permits.What is a VOC?A VOC is any compound that contains carbon and reacts withnitrogen oxides in the presence of sunlight to form ground-levelozone, a pollutant regulated by U.S. EPA. This ozone mixes withfine dust particles and other materials to form smog. Althoughozone is beneficial to the upper atmosphere, ground-level ozoneis an irritant that causes problems for humans, animals andplants. Because ground-level ozone is not emitted directly, U.S.EPA regulates the emissions of compounds that cause itsformation, namely VOCs, nitrogen oxides and other compounds.Many compounds, mainly solvents, are VOCs. There is not acomplete listing of all VOCs because the definition is so broad.Source: NASA – AuraHowever, some volatile compounds have negligible ozoneforming effects and are known as exempt VOCs. OhioAdministrative Code rule 3745-21-01 defines volatile organic compounds and includes a list of the compounds that arenot VOCs. For example, acetone, methylene chloride and many CFC refrigerants are not VOCs. When used as solvents incoating formulations, these exempt VOCs are commonly referred to as exempt solvents. U.S. EPA determines whichchemicals are exempt compounds and thus exempt from the federal definition of VOC. Ohio’s definition of VOC in OAC rule3745-21-01 is consistent with the federal definition.What is a HAP?Hazardous air pollutants (HAP), specified in Section 112(b) of the federal Clean Air Act, are those pollutants that cause ormay cause cancer or other serious health effects, such as reproductive effects or birth defects, or adverse environmentaland ecological effects. Many common solvents, such as xylene, toluene, and methyl isobutyl ketone are HAPs. In addition,pigment solids containing lead, cadmium, chromium, lead or other heavy metal compounds are also HAPs. A completelisting of all 187 HAPs can be found at epa.gov/ttn/atw/orig189.htmlWhat is a TAC?Ohio EPA defined 303 compounds that have known toxicological effects when emitted to the atmosphere. Many of thetoxic air contaminants on this list are also VOCs or HAPs that are commonly found in paints, coatings and solvents. LikeHAPs, TACs can be found in both the liquid and solid portions of coatings. The complete listing of the toxic aircontaminants regulated in Ohio can be found in OAC rule 3745-114-01.www.epa.ohio.gov/ocapp 50 W. Town St., Ste. 700 P.O. Box 1049 Columbus, OH 43216-1049 (614) 644-3020 (614) 644-2737 (fax)
Calculating Emissions from Coating and Painting OperationsHow are VOCs, HAPs, and TACs emitted?In general, coatings and paints are mixtures of liquid (volatile) and solid(non-volatile) materials. Resins and pigments usually make up the solidportion of the coating that forms the film that remains on the part after thecoating dries. The solids portion can contain HAPs and/or TACs, which arecommonly used in some types of pigments. HAPs and TACs present incoating solids are carried in the overspray that is typically captured byexhaust hoods or spray booths and filtered before being released to theambient air. A small amount of this overspray escapes the filters and isexhausted to the ambient air as particulate emissions.The liquid portion of the coating can consist of water, solvents, diluents,reducers and thinners. These compounds evaporate, or volatilize, duringthe application and drying processes. Typical hoods or booths capture thefumes and exhaust them to the ambient air. Most solvents, diluents andthinners are, or contain, VOCs, HAPs and TACs. These volatile compoundspass through common types of paint booth exhaust filters.How to Estimate VOC, HAP and TAC EmissionsThe use of a mass balance approach is the easiest way to calculate VOC, HAP and TAC emissions from a coating operation.This method uses coating formulation and usage data and assumes that all of the VOC, HAP and TAC contained in theliquid (volatile) portion of the coating is emitted into the air after the coating is applied and dried.To calculate emissions from the volatile portion of the coating, multiply the amount of VOC/HAP/TAC in a gallon ofcoating by the total gallons of coating applied during the time frame of interest, for example, hour, day, month, etc.Pounds of VOC emitted (pounds of VOC/gallon) x (gallons applied)[for any time frame]This calculation can be repeated for total HAP, single HAP and single TAC chemicals by using coating density and theweight percentage of each in the coating formulation. It is very important that you include any diluents, thinners orreducers mixed with the coating before application. These materials generally increase the VOC/HAP/TAC content of theapplied coating and overall emissions.To estimate HAP/TAC emissions from the solids (non-volatile) portion of the coating, multiply the coating density by theweight percentage of HAP/TAC in the coating, the amount of coating applied, the transfer efficiency*(TE) of the coatingequipment, and the exhaust filter efficiency (FE), if filters are present.Pounds solid HAP emitted (coating density) x (% wt HAP or TAC) x (gallons applied) x [1-TE] x [1-FE]*Transfer efficiency (TE) is defined as the ratio of the weight of coatings solids deposited on a substrate to the total weight ofcoatings solids put through the application equipment. TE is usually expressed as a percentage.How do I find the VOC, HAP and TAC content of coatings and solvents?The amounts of VOC, HAP and TAC in coatings and other materials should be available from the supplier or manufacturerin a data sheet (for example, Environmental Data Sheet (EDS), Technical Data Sheet, Product Specifications or CertifiedProduct Data Sheet) or through independent lab analysis.* Note that the product’s Material Safety Data Sheet (MSDS) mayor may not include this information in detail. The MSDS is not designed to provide this level of environmental information.*Lab analysis is rarely required. Contact your coating supplier and ask for the VOC, HAP and TAC content information if it isnot listed on the EDS or other data sheets.Page 2
Calculating Emissions from Coating and Painting OperationsWhat data do I need from the EDS or Technical Data Sheet?For air emission calculations, the information you need is usually found in the following sections of a typical EDS orsimilar type of product data sheet.Hazardous Ingredients/Composition SectionThis section typically contains a list of the material’s hazardous ingredients, their Chemical Abstract System (CAS)numbers, and their percent by weight or by volume. This section will help you identify if there are any HAPs or TACs inthe material. Sometimes a data sheet will list a range (e.g. Ethylbenzene 1-5% wt.) instead of an exact percentage. In suchinstances, contact the supplier for the precise value or simply use the highest value of the range listed.Be aware that a chemical may have several common names, so make special note of the CAS number typically listed on thedata sheet beside each chemical. You can positively identify each chemical by the using its unique CAS number.Product Weight or Material Density: This ishow much one gallon of the material weighs –it is not the VOC content.Specific gravity: Sometimes used in place ofmaterial density for liquids, this dimensionlessnumber compares the material’s density to thedensity of water. A specific gravity less than 1.0means the material is less dense (lighter) thanwater, greater than 1.0 means the material is moredense (heavier) than water.This column identifies ingredients that are HAPs,per Section 112 of the Clean Air Act, and showsethylbenzene is a HAP, while mineral spirits is not.CAS number, unique to eachchemicalPage 3
Calculating Emissions from Coating and Painting OperationsPhysical/Chemical Properties SectionThis section of the EDS contains some information about the material that is useful for air emission calculations. The keypieces of information are:Exempt solvents: Listed are anycompounds that are excluded fromthe definition of VOC. Water is notorganic and is the only exemptsolvent in this formulation.Total Volatiles: This number, typicallyexpressed as % by weight or % by volume,represents how much of the materialevaporates. It typically includes water, allVOCs, and exempt solvents combined.VOC content, total: Typically expressed aspounds of VOC per gallon (lbs VOC/gal) orgrams per liter (g/l). This is the numberneeded for VOC emission calculations.VOC content, less exempt solvents: This isthe value needed to determine if the coatingcomplies with a regulatory formulationlimit, e.g., 3.5 lbs VOC/gallon. It is not usedfor emission calculations.IMPORTANT: To greatly simplify the emission calculations, it is recommended that you obtain weight percentages (% byweight) for the VOC, HAP and TAC in each product. Percent by weight and percent by volume are not the same thing. If notlisted as percent by weight on the EDS or other technical data sheet, contact your supplier and ask for this information.What does VOC per gallon, excluding water and exempt solvents mean?Some coatings contain water as a solvent and/or some amounts of exempt solvents. EPA regulations typically limit theamount of VOC per gallon of coating, excluding water and exempt solvents. This is done to regulate the ratio of solids toVOC in the coating formulation since it is the VOC portion that contributes to air pollution. Check the EDS or othertechnical data to see if the coating contains water and exempt solvents and if the VOC content is expressed as lbs VOC/gal.,minus water and exempt solvents, or lbs/gal less exempt solvents. Although this value is useful for determining if thecoating meets a regulatory limit for its formulation, it is not typically used for emission calculations.Why does the EDS list two different VOC contents, and which one do I use for emission calculations?Sometimes, an EDS will list two or more different “VOC contents” with labels such as theoretical, total, actual, as-applied,as-mixed, minus water and exempt solvents, lbs/gal of solids, or less exempt solvents. These varying VOC contents typicallymean different things in terms of regulatory compliance. For emission calculations, use the value labeled theoretical, total,actual, as-applied, or as-mixed. This value represents the true mass of VOC in one gallon of coating.Page 4
Calculating Emissions from Coating and Painting OperationsWhat is a compliant coating?A compliant coating is one that meets a specific regulatory VOC per gallon limitation, e.g., 3.5 lbs VOC/gal, 3.0 lbs VOC/gal,etc., when it is mixed and applied. Many coating manufacturers include strict thinning or reducing instructions to ensurethe as-packaged and as-applied (mixed) VOC content of the coating does not exceed regulatory limits.What happens to the VOC content if I thin my coatings?Thinning a water-based coating with water does not change its VOC per gallon minus water value, since the added wateris subtracted in the calculation needed to see if it meets a VOC per gallon minus water limit. However, if you thin or reducea coating with a VOC-containing material, you will typically raise its overall VOC content and risk turning a compliantcoating (i.e., one that meets the VOC/gallon limit as packaged) into a non-compliant coating. See calculation Example 3.How do you calculate “VOC per gallon excluding water” to see if your coatings, as mixed and applied,comply with regulatory VOC per gallon, i.e., formulation, limits?Normally, the value shown on an EDS or Product Data Sheet for the material as “VOC content, less exempt solvents, or“VOC, less water” can be used to demonstrate compliance with regulatory formulation limits. However, if the coating ismixed with a VOC-containing thinner or reducer, you will likely change the VOC content and need to recalculate it todemonstrate compliance with formulation limitations. See the Ohio EPA Division of Air Pollution Control EngineeringGuides 45 and 48 for examples of this calculation.Which solvents or coating ingredients are considered “exempt solvents”?Exempt solvents are considered the same as water; that is, they are not VOCs. First, check the coating MSDS or EDS forexempt solvent information. The U.S. EPA researches and determines which solvents and compounds are exempt from thedefinition of VOC. Ohio EPA adopts these federal determinations and occasionally amends Ohio’s definition of VOC in OAC3745-21-01(B)(16) to add any new exempt compounds. Common exempt solvents found in coatings include acetone,methyl acetate, and t-butyl acetate.All of the coatings I use are water-based. Are there still VOC emissions?In most cases, yes. Many water-based coatings still contain some VOC, but this amount is usually small compared tosolvent-based coatings. Always check the coating EDS or product data sheets for the relevant VOC information.Where can I find Ohio EPA air pollution regulations?Air pollution regulations (complete list) - ve-rulesRegulations for surface coating (OAC 3745-21-01, 09, 10, 15, 18, 19, 20, 24, and 29) -epa.ohio.gov/dapc/regs/3745 21.aspxEngineering Guides - epa.ohio.gov/dapc/engineer/eguides.aspxPage 5
Calculating Emissions from Coating and Painting OperationsExample calculationsThe following example calculations demonstrate the most common calculations needed for air permit compliance andemissions reporting. It is not an exhaustive list of all possible calculations. Also see the Ohio EPA Division of Air PollutionControl Engineering Guides 45 and 48 for additional calculation examples.Useful Conversion Factorsgrams/liter 0.008344 lbs/gal1 liter 0.2642 U.S. gallonDensity of water 8.34 lbs/gallon1 pound 453.6 grams1 gallon 4 quarts 8 pints 128 fl. ouncesExample 1: Calculating the hourly VOC emission rate (lbs VOC/hr) for a straight, as-packaged (not reduced) coatingData needed:1) coating VOC content 2.71 lbs VOC/gallon from example EDS2) application rate 2.0 gallons/hourHourly VOC emission rate:2.71 lbs VOC/gal x 2.0 gal/hr 5.42 lbs VOC/hrExample 2: Calculating annual VOC emissions (tons VOC/yr) from all coating and cleanup operationsData needed:1) primer VOC content 2.80 lbs VOC/gallon from EDS; used 800 gallons/year2) top coat VOC content 3.47 lbs VOC/gallon from EDS; used 1,500 gallons/year3) clean up solvent VOC content 7.2 lbs VOC/gallon from EDS; used 100 gallons/yearAnnual VOC emissions:[2.80 lbs VOC/gal x 800 gal/yr] [3.47 lbs VOC/gal x 1500 gal/yr] [7.2 lbs VOC/gal x 100 gal/yr]2,000 lbs/ton 4.08tons/yrExample 3: Calculating the as-applied VOC content and emissions of a reduced (thinned) coatingData needed:1) topcoat VOC content 3.47 lbs/gallon from EDS2) reducer VOC content 6.5 lbs/gallon from EDS3) mix ratio 4 gallons topcoat to 1 gallon reducer4) mixed coating application rate 2.5 gallons/hourVOC of mixture:[4 gal x 3.47 lbs VOC/gal] [1 gal x 6.5 lbs VOC/gal]4 gal 1 gal 4.08 lbs VOC/gal, as mixedHourly VOC emission rate: 4.08 lbs VOC/gal x 2.5 gal/hr 10.2 lbs VOC/hrExample 4: Calculating the single HAP or TAC emission rate (lbs/hr) for a straight, as-packaged (not reduced) coatingData needed:1) product density 8.75 lbs/gallon from EDS2) HAP/toxic air contaminants in coating: xylene 5% by wt., and toluene 10% by wt. from EDS3) coating application rate 2.0 gallons/hourXylene emissions: 8.75 lbs/gal x 0.05 x 2.0 gal/hr 0.88 lb/hr xyleneToluene emissions: 8.75 lbs/gal x 0.10 x 2.0 gal/hr 1.75 lbs/hr toluenePage 6
Calculating Emissions from Coating and Painting OperationsExample 5: Calculating emissions (lbs/hr) of individual HAPs or TACs from a mixed coatingThese calculations require you to first identify any HAPs and TACs contained in the coatings and reducers. For thisexample, xylene, toluene and MIBK were identified on the EDS as HAPs. In addition, all three of these chemicals are also onthe TAC list specified in OAC 3745-114-01.Data needed:1)2)3)4)topcoat: product density 8.5 lbs/gal, 5% wt xylene, 8% wt MIBK from EDSreducer: product density 7.5 lbs/gal, 10% wt xylene, 20% wt toluene from EDSmix ratio 4 gallons topcoat to 1 gallon reducermixed coating application rate 2.5 gallons/hourXylene content of mixed coating:(8.5 lbs/gal x 0.05 x 4 gal) (7.5 lbs/gal x 0.10 x 1 gal)4 gal 1 gal 0.49 lb xylene/galToluene content of mixed coating:(7.5 lbs/gal x 0.20 x 1 gal)4 gal 1 gal 0.30 lb toluene/galMIBK content of mixed coating:(8.5 lbs/gal x 0.08 x 4 gal) 0.54 lb MIBK/gal4 gal 1 galXylene emissions: 0.49 lbs/gal X 2.5 gal/hr 1.23 lbs/hr xyleneToluene emissions: 0.30 lbs/gal X 2.5 gal/hr 0.75 lb/hr tolueneMIBK emissions: 0.54 lbs/gal X 2.5 gal/hr 1.35 lbs/hr MIBKExample 6: Calculating annual HAP and TAC emissions (tons/yr) from all coating and cleanup operationsThese calculations require you to first identify any HAPs and TACs contained in the coatings, reducers and cleanupsolvents. For this example, xylene, toluene and MIBK were identified on the EDS as HAPs. In addition, all three of thesechemicals are also on the TAC list specified in OAC 3745-114-01.Data needed:1) primer: density 8.5 lbs/gal, 5% wt xylene, 8% wt MIBK from EDS; used 800 gal/yr2) top coat: density 8.2 lbs/gal, 7% wt xylene, 10% wt toluene from EDS; used 1500 gal/yr3) clean up solvent: density 7.2 lbs /gal, 50% wt xylene, 50% toluene from EDS; used 100 gal/yrXylene emissions:(8.5 lbs/gal x 0.05 x 800 gal/yr) (8.2 lbs/gal x 0.07 x 1,500 gal/yr) (7.2 lbs/gal x 0.50 x 100 gal/yr) 0.78ton/yr2,000 lbs/tonxyleneToluene emissions:(8.2 lbs/gal x 0.10 x 1,500 gal/yr) (7.2 lbs/gal x 0.50 x 100 gal/yr)2,000 lbs/tonPage 7 0.80 ton/yr toluene
Calculating Emissions from Coating and Painting OperationsExample 7: Calculating emissions (lbs/hr) for solid HAP/TAC from a coatingThis calculation requires you to identify any non-volatile (solid) HAPs and TACs contained in the coating. For thisexample, lead oxide was identified on the EDS and is a HAP and a TAC (as a lead compound). Check with vendors fortransfer efficiency and filter efficiency information.Data needed:1)2)3)4)5)product density 9.75 lbs/gallon from EDSHAP/toxic air contaminants in coating: lead oxide 2% by wt. from EDScoating application rate 2.0 gallons/hourtransfer efficiency (TE) for HVLP spray equipment 65%, per HVLP vendorbooth filter efficiency (FE) 95%, per filter manufacturer documentationLead oxide emissions:9.75 lbs/gal x 0.02 x 2.0 gal/hr x [1 – 0.65] x [1 – 0.95] 0.007 lb/hr lead oxideExample 8: Calculating product density (lbs/gal) using the specific gravity (S.G.)Data needed:1) product specific gravity (S.G.) 1.17 from example EDS;2) density of water 8.34 lbs/gal from standard material density referencesProduct density: 1.17 x 8.34 lbs/gal 9.75 lbs/galPage 8
A compliant coating is one that meets a specific regulatory VOC per gallon limitation, e.g., 3.5 lbs VOC/gal, 3.0 lbs VOC/gal, etc., when it is mixed and applied. Many coating manufacturers include strict thinning or reducing instructions to ensure the as-packaged and as-applied (mixed) VOC content of the
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